Comparative Structural Performance Analysis of Castellated and Rolled Steel Beams in Pre-Engineered Building Systems

This study investigates the structural performance of castellated beams integrated into Pre-Engineered Building (PEB) systems and compares them with conventional rolled steel beams using finite element analysis (FEA). Castellated beams, created by introducing web openings in rolled I-sections, enhance load-carrying capacity, stiffness, and material efficiency, making them particularly suitable for long-span applications. The research analyzes parameters such as total deformation, normal stress, shear stress, and strain distribution under different loading conditions, adhering to IS 800:2007 and IS 875 design provisions. Results reveal that castellated beams significantly reduce stresses and deformations compared to tapered sections, demonstrating improved strength-to-weight ratios and cost efficiency. However, stress concentration around openings highlights the necessity for optimized hole geometry and detailing to prevent local failure. The case study of a PEB shed in Pune validates the applicability of castellated beams in real-world conditions, emphasizing their role in minimizing foundation loads and enhancing serviceability. Overall, castellated beams emerge as a sustainable and economical solution for modern steel construction, offering superior performance when reinforced with proper design modifications. The findings contribute valuable insights for updating design codes and guiding practical applications in industrial and commercial infrastructure.